Pallet

ABSTRACT

A pallet includes a deck and a plurality of columns extending downwardly from the deck. The columns have interiors that open upwardly through the deck, such that the pallet is nestable, i.e. the columns of a similar pallet will be at least partially received within the columns of the pallet when stacked thereon. A plurality of running boards are removably connectable to the bottoms of the columns. A plurality of reinforcement pockets are molded into an upper surface of the deck.

The application claims priority to U.S. Provisional Application No. 60/716,019 which was filed on Sep. 9, 2005.

BACKGROUND OF THE INVENTION

This invention relates to a pallet. Pallets are often used to store and transport goods. Pallets maintain the goods at a distance above the floor such that they can readily be lifted and moved by a forklift. Plastic pallets are lighter and more durable than wooden pallets. Some plastic pallets include a deck from which a plurality of columns extends downwardly. Fork-receiving openings are defined between the columns.

Some plastic pallets are nestable, i.e. the columns of an empty pallet are partially received within the columns of an empty pallet stacked there below. This reduces the overall stacking height of the empty pallets.

Other pallets include a lower deck or stringers (or running boards) connecting the bottoms of the columns. This improves the stability of the loaded pallets when stacked. However, the stringer pallets do not nest when empty and therefore have a higher stacking height.

SUMMARY OF THE INVENTION

A pallet according to one embodiment of the present invention includes a deck and a plurality of columns extending downwardly from the deck. The columns have hollow interiors that open upwardly through the deck, such that the pallet is nestable, i.e. the columns of a similar pallet will be at least partially received within the columns of the pallet when stacked thereon.

A plurality of running boards is removably connectable to the bottoms of the columns. The running boards improve the stability of the pallet when stacked with other loaded pallets. Prior to connection to a pallet, the running boards are nestable with one another when stacked.

The pallet deck includes a plurality of reinforcement pockets formed therein between adjacent pair of columns. The reinforcement pockets increase the stiffness and strength of the deck, while permitting the pallet to be molded as a single part.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of a pallet according to the present invention.

FIG. 2 is top view of the pallet.

FIG. 3 is a bottom view of the pallet.

FIG. 4 is an end view of the pallet.

FIG. 5 is a side view of the pallet.

FIG. 6 is a perspective view the pallet of FIG. 1 connected to a plurality of running boards.

FIG. 7 is an end view of the pallet and running boards of FIG. 6.

FIG. 8 is a side view of the pallet and running boards of FIG. 6.

FIG. 9 is a bottom view of the pallet and running boards of FIG. 6.

FIG. 10 is a top view of the pallet and running boards of FIG. 6.

FIG. 11 is a perspective view of the pallet of FIG. 1 nested with a similar pallet.

FIG. 12 is a perspective view of a second embodiment of the running boards of FIG. 6.

FIG. 13 is a perspective view of the running board of FIG. 12 nested with a similar running board.

FIG. 14 is a side view of the running boards of FIG. 13.

FIG. 15 is a sectional view of the running boards of FIG. 14.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A pallet 10 according to the present invention is shown in FIG. 1. The pallet 10 includes a deck 12 from which extend downwardly a plurality of corner columns 14 a, side columns 14 b, end columns 14 c and a center column 14 d, henceforth collectively referenced generally as “columns 14.” Each column 14 defines an interior 15 opening upwardly through the deck 12. The deck 12 includes a lip 16 extending downwardly from a peripheral edge of the deck 12.

A plurality of reinforcement pockets 18 are molded into the upper surface of the deck 12 between each adjacent pair of columns 14. Each reinforcement pocket 18 extends from one column 14 to the adjacent column 14 and includes a pair of opposed side walls 20, a pair of opposed end walls 22, perpendicular ribs 24 and a floor 26. The floor 26 is generally parallel to the upper surface of the deck 12 and in a plane spaced downwardly from the upper surface of the deck 12.

FIG. 2 is a top view of the pallet 10. FIG. 3 is a bottom view of the pallet 10. Each column 14 includes a peripheral wall 30 and a bottom wall 32. A pair of apertures 34 are formed through the bottom wall 32.

Referring to FIG. 3, a plurality of small gussets 36 extend from the lip 16 of the deck 12 to the side walls 20 of the reinforcement pockets 18. The gussets 36 reinforce the periphery of the deck 12 outward of the reinforcement pockets 18. The gussets 36 also provide angled leading surfaces for contact with the forks of a forklift lifting the pallet 10, to reduce the force of impact of the forks with the deck 12 and/or reinforcement pockets 18.

FIG. 4 is an end view of the pallet 10. FIG. 5 is a side view of the pallet 10. Each of the columns 14 includes a plurality of notches 38 formed in each side of the column 14. In the embodiment shown, the notches 38 are not formed in the ends of the columns 14, but could be formed in the ends in addition to or instead of the sides.

FIG. 6 is a perspective view the pallet 10 of FIG. 1 connected to a plurality of running boards 40. Each of the running boards 40 includes a plurality of pockets 42 connected by runners 44.

FIG. 7 is an end view of the pallet 10 and running boards 40 of FIG. 6. FIG. 8 is a side view of the pallet 10 and running boards 40 of FIG. 6. FIG. 9 is a bottom view of the pallet 10 and running boards 40 of FIG. 6.

FIG. 10 is a top view of the pallet 10 and running boards 40 of FIG. 6. Snap-fit tabs 46 of the running boards 40 (FIG. 9) are snap-fit into the apertures 34 in the bottom walls 32 of the columns 14 to removably secure the running boards 40 (FIG. 9) to the pallet 10.

FIG. 11 is a perspective view of the pallet 10 of FIG. 1 nested with a similar pallet 10′. The columns 14′ of the upper pallet 10′ are partially received within the interiors 15 of the columns 14 of the pallet 10. This reduces the overall stacking height of the empty pallets 10, 10′.

FIG. 12 is a perspective view of a second embodiment of one of the running boards 40 of FIGS. 6-10. Each of the pockets 42 includes two pair of flexible snap-fit tabs 46 projecting upwardly from the bottom wall of the pocket 42. Each pocket 42 further includes two opposing pair of protrusions 48 into the pocket 42. The running board 40 is identical to those in FIGS. 6-10, with the exception that it further includes a pair of pyramids 50 projecting upwardly from the runners 44 adjacent each outer pocket 42. The pyramids 50 interlock with a recess on the underside of a similar running board 40′ stacked thereon as shown in FIG. 13.

FIG. 13 is a perspective view of the running board 40 of FIG. 7 nested with a similar running board 40′. FIG. 14 is a side view of the running boards 40, 40′ of FIG. 13. FIG. 15 is a sectional view of the running boards 40, 40′ of FIG. 14. The pyramids 50 of the lower running board 40 are partially received within recesses on the underside of the upper running board 40′, such that ribs 52′ projecting downwardly from the runner 44′ are interlocked between the pyramids 50, for more stable stacking of multiple running boards 40, 40′.

The pallet 10 and runners 40 may be injection molded, compression molded, thermoformed, twin sheet thermoformed or formed by some other suitable process of a plastic, such as polypropylene or HDPE.

While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. 

1. A pallet comprising: a deck; a plurality of columns extending downwardly from the deck; and at least one running board removably secured to the plurality of columns.
 2. The pallet as recited in claim 1, wherein the at least one running board includes a plurality of pockets connected by a plurality of runners.
 3. The pallet as recited in claim 2, wherein the plurality of columns are removably secured within the plurality of pockets.
 4. The pallet as recited in claim 3, wherein the at least one running board includes at least one snap-fit tab that is snap-fit into an aperture formed in a bottom wall of one of the plurality of columns.
 5. The pallet as recited in claim 1, wherein at least one of the plurality of pockets includes a pair of snap-fit tabs.
 6. The pallet as recited in claim 5, wherein the pair of snap-fit tabs extends upwardly from a bottom wall of the at least on pocket.
 7. The pallet as recited in claim 6, wherein the at least one of the plurality of pockets further includes two opposing pair of protrusions.
 8. The pallet as recited in claim 1, wherein the at least one running board includes a first running board and a second running board, wherein the first running board includes a pair of pyramids projecting upward from a topside of the first running board.
 9. The pallet as recited in claim 8, wherein the second running board includes at least one recess disposed in an underside of the second running board.
 10. The pallet as recited in claim 9, wherein when the first running board and the second running board are removed from the plurality of columns and the second running board is stacked on the first running board, the pair of pyramids of the first running board are partially received within the at least one recess of the second running board.
 11. A pallet comprising: a deck including an upper surface and at least one reinforcement pocket molded therein; and a plurality of columns extending downwardly from the deck.
 12. The pallet as recited in claim 11, wherein the plurality of columns includes at least one pair of adjacent columns and the at least one reinforcement pocket extends between the pair of adjacent columns.
 13. The pallet as recited in claim 12, wherein the at least one reinforcement pocket includes a pair of opposed side walls and a pair of opposed end walls.
 14. The pallet as recited in claim 13, wherein the at least one reinforcement pocket further includes at least one rib, wherein the rib is substantially perpendicular to a floor.
 15. The pallet as recited in claim 14, wherein the floor is generally parallel to the upper surface of the deck and in a plane spaced downwardly from the upper surface of the deck.
 16. The pallet as recited in claim 15, wherein the plurality of columns associated with at least one pallet are partially received within interiors of a second plurality of columns associated with another pallet.
 17. The pallet as recited in claim 15, further including at least one running board removably secured to the plurality of columns.
 18. The pallet as recited in claim 17, wherein the at least one running board includes a plurality of pockets and a plurality of runners disposed between the plurality of pockets.
 19. The pallet as recited in claim 18, wherein the plurality of columns are received within the plurality of pockets.
 20. The pallet as recited in claim 13, further including a plurality of gussets, wherein the deck includes a lip and at least one of the plurality of gussets extends from the lip of the deck to at least one of the pair of opposed side walls.
 21. The pallet as recited in claim 20, wherein at least one of the plurality of gussets includes at least one angled surface for contact with forks of a forklift.
 22. The pallet as recited in claim 11, wherein each of the plurality of columns includes a peripheral wall, a bottom wall, and a pair of apertures.
 23. The pallet as recited in claim 22, wherein the pair of apertures is formed through the bottom wall.
 24. The pallet as recited in claim 23, further including at least one running board removably secured to the plurality of columns via the pair of apertures.
 25. The pallet as recited in claim 11, wherein each of the plurality of columns includes a pair of opposed side walls and a pair of opposed side walls and at least one of the plurality of columns includes a plurality of notches formed in each of one of the pair of opposed side walls and the pair of opposed end walls.
 26. A running board comprising: a plurality of pockets connected by at least one runner.
 27. The running board as recited in claim 26, further including at least one tab for engagement with at least one aperture of a pallet for removably securing the running board to the pallet.
 28. The running board as recited in claim 27, wherein the at least one tab is disposed within at least one of the plurality of pockets.
 29. The running board as recited in claim 27, wherein the at least one tab is a snap-fit tab.
 30. The running board as recited in claim 26, wherein the plurality of pockets includes a first pocket, a second pocket and a third pocket; and the at least one runner includes a pair of runners, wherein one of the pair of runners extends between the first pocket and the second pocket and the other of the pair of runners extends between the second pocket and the third pocket.
 31. The running board as recited in claim 30, further including at least one pair of tabs disposed with at least one of the first pocket, the second pocket and the third pocket for engagement with at least one aperture of a pallet for removably securing the running board to the pallet. 